mt and vt cimolai technology

TECHNICAL REPORT Magnetic Testing in the welds of

the Upper Wagon Central Deck

Rev: 0 March 2015 of 17

WDS INGENIERIA, S.A. Inspected by: Report written by: Report reviewed by:

ENG. Wisthon Cuicas ENG. Wisthon Cuicas ENG. Daniel Rivero

Calle Ferrer Arias, Edif Dos Mares View, Apto 2D, Dos Mares, Ciudad de Panamá +507 391 0946 / +507 6668 1761 [email protected]

TECHNICAL REPORT

Magnetic Testing and Visual Testing Inspection and

Reinspection to the welds of the Upper Wagon Central

Deck Q1000/C an Q1000/D

March 2015







Panama, March 2015

Gentlemen: Cimolai Technology, S. p. A.

Attention. Alessandro Boscaro.

REF: Magnetic Testing Inspection and Reinspection of welds of Upper Wagon Central Deck

Cot C1502-021S

Respected Engineer

Attached Technical Magnetic Testing Report, by WDS Ingeniería, S.A.,

Testing conducted in welds of Upper Wagon Central Deck in the Panama

Canal expansion.

This report contains observations and conclusions relating to the service.

Best regards

ENG. Daniel Rivero

ASNT-TC-1A Level II PT, VT, MT. Level II UT, ECT

AWS Member No 675950







CONTENT.

1. OBJECTIVE

2. INSPECTION DATE, PERSONNEL AND EQUIPMENTS

3. DEFINITIONS

4. PROCEDURE

5. ACCEPTANCE AND REJECT CRITERIA

6. INSPECTION RESULTS

7. CONCLUSSIONS

8. ANNEXES







1. OBJECTIVE.

Evaluate the condition of the welds of the Upper Wagon Central Deck,

trough magnetic testing (MT).

2. INSPECTION DATE, PERSONNEL AND EQUIPMENTS.

The inspections were made on March 4th 2015.

The personnel involved in the testing was:

- Eng Cuicas Wisthon, ASNT-TC-1A Level II: VT, PT, MT, and UT.

The equipment used was:

- AWS Weld Gauge Kit

Magnetic Test (MT)

- MAGNAFLUX red magnetic particles (Dry).

- MAGNAFLUX Magnetic Yoke, Serial # 1858.







3. DEFINITIONS.

Principle: The magnetic particle method is based on establishing a magnetic field with high flux density in a ferromagnetic material. The flux

lines must spread out when they pass through non-ferromagnetic material such as air in a discontinuity or an inclusion. Because flux lines cannot

cross, this spreading action may force some of the flux lines out of the material (flux leakage). Flux leakage is also caused by reduction in

ferromagnetic material (cross-sectional change), a Sharp dimensional

change, or the end of the part. If the flux leakage is strong enough, fine magnetic particles will be held in place and an accumulation of particles

will be visible under the proper lighting conditions. While there are variations in the magnetic particle method, they all are dependent on this

principle, that magnetic particles will be retained at the locations of magnetic flux leakage. The amount of flux leakage at discontinuities

depends primarily on the following factors; flux density in the material, and size, orientation, and proximity to the surface of a discontinuity. With

longitudinal fields, all of the flux lines must complete their loops though air and an excessively strong magnetic field may interfere with

examination near the flux entry and exit points due to the high flux-density present at these points.

Method: there are three steps essential to the method:

The part must be magnetized. Magnetic particles of the type designated in the contract/purchase

order/specification should be applied while the part is magnetized or immediately thereafter.

Any accumulation of magnetic particles must be observed, interpreted, and evaluated.

Ways to Magnetize: A ferromagnetic material can be magnetized either

by passing an electric current through the material or by placing the

material within a magnetic field originated by an external source. The

entire mass or a portion of the mass can be magnetized as dictated by







size and equipment capacity or need. As previously noted, in order to be

detectable, the discontinuity must interrupt the normal path of the

magnetic field lines. If a discontinuity is open to the surface, the flux

leakage attracting the particles will be at the maximum value for that

particular discontinuity. When that same discontinuity is below the

surface, flux leakage evident on the surface will be a lesser value.

Field Direction: If a discontinuity is oriented parallel to the magnetic

field lines, it may be essentially undetectable. Therefore, since

discontinuities may occur in any orientation, it may be necessary to

magnetize the part or the area of interest twice or more sequentially in

different directions by the same method or a combination of different

methods to induce magnetic field lines in a suitable direction in which to

perform an adequate examination.

Field Strength: The magnetic field must be of sufficient strength to

indicate those discontinuities which are unacceptable, yet must not be so

strong that an excess of local particle accumulation masks relevant

indications

Types of Magnetic Particles and Their Use: There are various types

of magnetic particles available for use in magnetic particle testing. They

are available as dry powders (fluorescent and nonfluorescent) ready for

use as supplied, powder concentrates (fluorescent and nonfluorescent)

for dispersion in water or suspending in light petroleum distillates,

magnetic slurries/paints, and magnetic polymer dispersions.

Evaluation of Indications: When the material to be examined has been

properly magnetized, the magnetic particles have been properly applied,

and the excess particles properly removed, there will be accumulations of

magnetic particles remaining at the points of flux leakage. These

accumulations show the distortion of the magnetic field and are called

indications. Without disturbing the particles, the indications must be







examined, classified, compared with the acceptance standards, and a

decision made concerning the disposition of the material that contains the

indication.

Typical Magnetic Particle Indications:

Surface Discontinuities: Surface discontinuities, with few

exceptions, produce sharp, distinct patterns.

Near-surface discontinuities: Near-surface discontinuities

produce less distinct indications than those open to the surface. The

patterns tend to be broad, rather than sharp, and the particles are

less tightly held.

Yokes: Yokes are usually C-shaped electromagnets which induce a

magnetic field between the poles (legs) and are used for local

magnetization. Many portable yokes have articulated legs (poles) that

allow the legs to be adjusted to contact irregular surfaces or two surfaces

that join at an angle.

USE A YOKE AS TOOL FOR INSPECTION

Yoke: Examination of large surface areas for surface-type discontinuities.

Advantages Limitations

1. No electrical contact.

2. Highly portable.

3. Can locate

discontinuities in any

direction with proper

orientation.

1. Time consuming.

2. Must be

systematically

repositioned in view of

random discontinuity

orientation.

Yoke, dry powders







Dry Particles: Dry magnetic powders are designed to be used as supplied

and are applied by spraying or using directly onto the surface of the part

being examined. They are generally used on an expendable basis because

of the requirement to maintain particle size and control possible

contamination. Reuse is not a normal practice. Dry powders may also be

used under extreme environmental conditions. They are not affected by

cold; therefore examination can be carried out at temperatures that would

thicken or freeze wet baths. They are also heat resistant; some powders

may be usable at temperatures up to 600°F (315°C). Some colored,

organic coatings applied to dry particles to improve contrast lose their

color at temperatures this high, making the contrast less effective.

Fluorescent dry particles cannot be used at this high a temperature; the

manufacturer should be contacted for the temperature limitations.

USE A DRY PARTICLES FOR INSPECTION

Advantages Disadvantages

The dry magnetic particle technique is

generally superior to the wet technique for

detection of near-surface discontinuities on

parts with a gross indication size:

(a) for large objects when using portable

equipment for local magnetization;

(b) superior particle mobility is obtained for

relatively deep-seated flaws using halfwave

rectified current as the magnetizing source;

(c) easy for removal.

The dry magnetic particle technique:

(a) cannot be used in confined areas without

proper safety breathing apparatus;

(b) can be difficult to use in overhead

magnetizing positions;

(c) does not always leave evidence of complete

coverage of part surface as with the wet

technique;

(d) is likely to have lower production rates

than the wet technique; and

(e) is difficult to adapt to any type of automatic

system.

Dry Continuous Magnetization Technique: Unlike a wet suspension,

dry particles lose most of their mobility when they contact the surface of

a part. Therefore, it is imperative that the part/area of interest be under

the influence of the applied magnetic field while the particles are still

airborne and free to be attracted to leakage fields. This dictates that the

flow of magnetizing current be initiated prior to the application of dry

magnetic particles and terminated after the application of powder has







been completed and any excess has been blown off. Magnetizing with HW

current and AC current provide additional particle mobility on the surface

of the part. Examination with dry particles is usually carried out in

conjunction with prod-type or yoke localized magnetizations, and buildup

of indications is observed as the particles are being applied.

4. PROCEDURE.

The procedure is developed based on the standard ASTM E-709-08. What

is summarized in the following steps:

a. Cleaning the inspection area (Chapter 9).

b. Continues magnetization in one direction (using the electromagnetic

yoke).

c. Application of the visible particles (red) dry powder.

d. First evaluation (Chapters 10 and 16).

e. Continues magnetization perpendicular to the first direction of

assessment (using the electromagnetic yoke).

f. Final evaluation (Chapters 10 and 16).

g. Demagnetization (Chapter 18).

h. Cleaning post evaluation (Chapter 19).

i. Demarcation of indications.

j. Filling of the sheet technical report. In accordance with Chapters 17 and

21 of ASTM E-709-08.

5. ACCEPTANCE OR REJECT CRITERIA.

Acceptance or reject criteria was according to AWS D1.1 STRUCTURAL

WELDING CODE.

6. INSPECTION RESULTS.

During the Magnetic Testing (MT) and Visual Testing (VT) of the

100% of the welds belonging to Upper Wagon Central Deck Q1000/D and

Q1000/C relevant discontinuities were detected and repaired.







Magnetic Testing (MT) and Visual Testing (VT)

Inspection of the welds of the Upper Wagon Central Deck Q1000/C

Weld Stamping Defects determination Result

Ubication Length Accept Reject

W1 N/A Superficial 160mm X

W2 N/A X

W3 N/A X

W4 N/A Superficial 160mm and 80mm

X

W5 N/A 160mm and 30mm

X

W6 N/A X


W8 N/A Superficial 100mm

and 30mm

X

COMMENTS:

MADE BY REVIEWED BY APPROVED BY

COMPANY

SIGNATURE

NAME ENG. Wisthon Cuicas ENG. Wisthon Cuicas ENG. Daniel Rivero

DATE 03-09-2015 03-09-2015 03-09-2015








Reinspection in the welds of the Upper Wagon Central Deck Q1000/C



W1 N/A X

W4 N/A X

W5 N/A X

W7 N/A X

W8 N/A X

COMMENTS:


COMPANY

SIGNATURE


DATE 03-09-2015 03-09-2015 03-09-2015








Inspection of the welds of the Upper Wagon Central Deck Q1000/D



W1 N/A Superficial 160mm and 70mm

X

W2 N/A X

W3 N/A Superficial 21mm and

30mm

X

W4 N/A X

W5 N/A Superficial 45mm,

20mm and 85mm

X


65mm

X



60mm

X

COMMENTS:


COMPANY

SIGNATURE


DATE 03-09-2015 03-09-2015 03-09-2015








Reinspection in the welds of the Upper Wagon Central Deck Q1000/D



W1 N/A X

W3 N/A X

W5 N/A X

W6 N/A X

W7 N/A X

W8 N/A X

COMMENTS:


COMPANY

SIGNATURE


DATE 03-09-2015 03-09-2015 03-09-2015







7. GENERAL CONCLUSIONS.

All indications found were repaired. All welds were APPROVED after the repairment.







8. ANNEXES







PHOTOGRAPHIC RECORD

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